Jonathan A. Mackey

Uncertainty in Inverted Pendulum Thrust Measurements

An uncertainty analysis of a common configuration of electric propulsion thrust stand is presented. The analysis applies to inverted pendulum thrust stands operating in a null-coil configuration with in-situ calibration. Several sources of bias and precision uncertainty are discussed, propagated, and combined to form conservative estimates of the relative and absolute thrust uncertainties. A case study of the NASA Glenn Research Center Vacuum Facility 6 thrust stand is presented. For the thruster investigated, the uncertainty was estimated to be ±6.9mN over the entire span of thrust. This uncertainty represents a maximum instrument bias introduced by the thrust stand. The paper does not address repeatability of actual thrust measurements, as this is generally beyond the influence of the thrust stand and can be dependent on a large number of factors.

Diagnostic for Verifying the Thrust Vector Requirement of the AEPS Hall-Effect Thruster and Comparison to the NEXT-C Thrust Vector Diagnostic

A diagnostic has been designed and fabricated to verify the thrust vector requirement for the Advanced Electric Propulsion System (AEPS) Hall-effect thruster. This diagnostic will be used to verify that the propulsion system thrust vector offset from the mounting surface normal vector does not exceed 1.5 degrees over the entire throttling range and over the course of 23,000 hours of thruster testing. The diagnostic will not violate the thruster’s required voltage standoff capability in the presence of carbon backsputter by being minimally intrusive and not significantly adding to the facility backsputtered rate. Based on AEPS requirements and numerous facility considerations, an appropriate thrust vector diagnostic design was determined and comprises of a linear array of 23 Faraday probes swept through the plume in a semicircular arc 1 meter from the thruster center, which maps the beam current density. The beam current density centroid of the plume is assumed to track the thrust vector within an acceptable level of uncertainty. Additionally, a reference system, including optical alignment to the mounting surface normal vector and tilt sensors, was devised to periodically calibrate the probe position and motion throughout the long duration wear test campaign. Initial measurements of the thruster plume have been acquired to demonstrate the diagnostic’s functionality, verify procedures, and assess any necessary improvements prior to implementation of the diagnostic during the AEPS Engineering Development Unit (EDU) long duration wear test. To illustrate the merits of differing approaches to thrust vector determination for different classes of electric propulsion thrusters, NASA’s Evolutionary Xenon Thruster-Commercial (NEXT-C) thrust vector diagnostic design details and recent data are also discussed (Appendix A).

Iodine Hall-Effect Electric Propulsion System Research, Development, and System Durability Demonstration [STUB]

This paper reviews recent iodine electric propulsion research and development activities at the NASA Glenn Research Center (GRC). Activities included (i) investigation of the iodine compatibility of BaO-CaO-Al2O3 impregnated tungsten hollow cathodes based on a flight heritage design, (ii) investigation of the iodine compatibility of a handful of materials common to propulsion systems, spacecraft, and ground test facilities, (iii) development of reliable iodine feed system technologies, (iv) implementation of test facility improvements in an attempt to mitigate iodine associated negative impacts, and culminated in (v) an 1,174-hr hybrid iodine-xenon propulsion system durability demonstration (iodine fed Hall-effect thruster with xenon fed cathode). Each of the activities resulted in extensive insights that shall inform future iodine electric propulsion developments. While reliable operation of a BaO-CaO-Al2O3 impregnated tungsten hollow cathode on iodine vapor was not achieved, long-term operation on xenon gas in proximity to an iodine fed thruster was demonstrated without any measurable degradation or cross-contamination of the cathode. Furthermore, iodine material corrosion investigations conducted at 300 °C over 5, 15, and 30 days showed significant deterioration of all materials evaluated, although the same materials with a silicon coating proved nearly impervious to iodine so long as the coating was not mechanically damaged. Finally, the 1,174-hr durability test demonstration showed that (i) iodine feed system technologies developed at GRC delivered well-regulated uninterrupted propellant, (ii) implementation of appropriate facility improvements and procedures can limit negative impacts of iodine on test hardware and ground support equipment, although facility challenges with iodine are extensive, and (iii) a Hall-effect thruster operates with similar performance whether employing iodine or xenon propellant over long durations. The work was motivated by strong government and commercial interest in the growing capabilities of small-spacecraft (<500 kg), in combination with interest for denser lowpower, high delta-v in-space propulsion systems. This work adds to a growing body of research and development efforts aimed at addressing the many anticipated challenges of implementing iodine as an in-space propellant. This work was conducted under the Advanced In-Space Propulsion (AISP) project funded through the Game Changing Development (GCD) program within NASA’s Science Technology Mission Directorate (STMD).

In-situ Diagnostic for Assessing Hall Thruster Wear

The design of a new diagnostic to measure the net erosion of Hall thruster surfaces is presented. This diagnostic consists of a pair of optical noncontact profilometer pens mounted to a set of motion stages, which can interrogate the surface features of multiple components of interest including the hollow cathode assembly, magnet front pole covers, and discharge channel. By comparing scans of these surfaces to reference features, estimates of the component erosion rates can be acquired throughout long-duration lifetime tests without venting and removing the thruster from the vacuum facility for external profilometry. This work presents a detailed overview of the diagnostic design including the precision positioning system. In addition, preliminary data are shown which verify diagnostic operation and establish a baseline that will be used to track the erosion of the Hall Effect Rocket with Magnetic Shielding (HERMeS) Technology Demonstration Unit 3 (TDU-3) during an ongoing long-duration wear test.